Fuel injection valve

ABSTRACT

A coil is located radially outside of a pipe. An inner connector is located radially inside of the pipe. A moving core is located radially inside of the pipe and opposed to the inner connector. A housing surrounds both an outer circumferential periphery of the coil and one axial end of the coil. A cover surrounds an other axial end of the coil. An outer connector leads fuel into the pipe. The pipe and the cover are integrally formed and one single component as a with-cover pipe member. The inner connector and the outer connector are integrally formed and an other single component as a connector member. The connector member is partially inserted in the axial direction radially inside the pipe of the with-cover pipe member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and incorporates herein by referenceJapanese Patent Application No. 2007-300559 filed on Nov. 20, 2007.

FIELD OF THE INVENTION

The present invention relates to a fuel injection valve for an internalcombustion engine.

BACKGROUND OF THE INVENTION

For example, U.S. Pat. No. 7,051,960 B2 (JP-A-2006-22721) discloses afuel injection valve for an internal combustion engine. Conventionally,as shown in FIG. 3, a fuel injection valve (injector) 91 includes a pipe911, an inner connector 921, a moving core 923, a needle 940, and anouter connector 922. The inner connector 921 is located around the innercircumferential periphery of the pipe 911. The moving core 923 isopposed to the inner connector 921 in the axial direction and configuredto be drawn toward the inner connector 921 by exerted with magneticattraction force generated between the inner connector 921 and themoving core 923. The needle 940 as a valve element is movable togetherwith the moving core 923 in the axial direction and configured to openand close nozzle holes 934 to inject fuel. The outer connector 922 isconfigured to lead fuel into the pipe 911 from the outside of the outerconnector 922.

In the present conventional structure shown in FIG. 3, the pipe 911 ofthe injector 91 has the inner circumferential periphery accommodatingthe inner connector 921, the moving core 923, and the needle 940. Theinner connector 921 is located at the side of a rear end of the pipe911. The moving core 923 and the needle 940 are located at the side of atip end side of the pipe 911 with respect to the inner connector 921.The outer connector 922 is partially inserted into the rear end of thepipe 911. A coil 951 is provided around the outer circumferentialperiphery of the pipe 911 and configured to generate a magnetic fieldwhen being energized. A housing 913 surrounds the outer circumferentialperiphery of the coil 951 and one axial end of the coil 951 in the axialdirection, thereby supporting the coil 951. A cover 960 surrounds theother axial end of the coil 951 in the axial direction. That is, in thepresent structure of the injector 91 shown in FIG. 3, the coil 951 isenclosed by the pipe 911, a cover 912, and the housing 913. In thepresent structure, the nozzle holes 934 are located at the tip end side,and the opposite side of the nozzle holes 934 corresponds to the rearend side.

However, the fuel injection valve (injector) 91 of FIG. 3 has thefollowing problems. A large number of components of the injector 91 needto be inserted and accommodated inside the inner circumferentialperiphery of the pipe 911. In addition, components of the injector 91need to be attached to the outer circumferential periphery of the pipe911. Accordingly, productivity of the injector is impaired due toincrease and complication in the assembling process and the like. Inaddition, the present problem becomes further remarkable as the numberof components increases, and consequently productivity is furtherimpaired.

SUMMARY OF THE INVENTION

In view of the foregoing and other problems, it is an object of thepresent invention to produce a fuel injection valve having a simplestructure and excellent in productivity and quality.

According to one aspect of the present invention, a fuel injection valvecomprises a pipe being substantially in a cylindrical shape. The fuelinjection valve further comprises a coil located radially outside of thepipe and configured to generate a magnetic field when being energized.The fuel injection valve further comprises an inner connector locatedradially inside of the pipe. The fuel injection valve further comprisesa moving core located radially inside of the pipe and opposed to theinner connector, the moving core configured to be attracted to the innerconnector by magnetic attraction force generated between the moving coreand the inner connector. The fuel injection valve further comprises avalve element movable together with the moving core in an axialdirection and configured to open and close a nozzle hole for injectingfuel. The fuel injection valve further comprises a housing surroundingboth an outer circumferential periphery of the coil and one axial end ofthe coil, which is at one end side in the axial direction. The fuelinjection valve further comprises a cover surrounding an other axial endof the coil, which is at an other end side in the axial direction. Thefuel injection valve further comprises an outer connector configured tolead fuel from an outside of the pipe into the pipe. The pipe and thecover are integrally formed and one single component as a with-coverpipe member. The inner connector and the outer connector are integrallyformed and an other single component as a connector member. Theconnector member is partially inserted in the axial direction radiallyinside the pipe of the with-cover pipe member and connected with thepipe.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will become more apparent from the following detaileddescription made with reference to the accompanying drawings. In thedrawings:

FIG. 1 is a sectional view showing an injector according to a firstembodiment;

FIG. 2 is a graph showing a relationship between a cover thickness t2and static attraction force, according to a second embodiment; and

FIG. 3 is an injector according to a prior art.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS First Embodiment

A fuel injection valve (injector) according to the present embodiment isdescribed with reference to drawings. As shown in an FIG. 1, an injector1 in the present embodiment is applied to a direct-injection gasolineengine. The application of the injector 1 is not limited to thedirect-injection gasoline engine and may be applied to a premix gasolineengine or a diesel engine. The injector 1 is mounted to an engine head(not shown) when being applied the direct-injection gasoline engine. Inthe present embodiment, the injector 1 has a tip end sides to whichnozzle holes 34 are provided, and a rear end side at the opposite sideof the tip end side.

The injector 1 includes a with-cover pipe member 10 including a pipe 11and a cover 12. The pipe 11 is substantially in a cylindrical shape. Thecover 12 is projected from a rear end of the pipe 11 in a radialdirection. That is, in the present embodiment, the pipe 11 and the cover12 are integrated to be the with-cover pipe member 10 as one component(single component). The with-cover pipe member 10 is formed from amagnetic material such as electromagnetic stainless steel.

A coil assembly 50 is provided around the outer circumferentialperiphery of the pipe 11 of the with-cover pipe member 10. The coilassembly 50 is integrally formed of a coil 51, a mold element 52, and anelectrical connector 53. The coil 51 is covered with the mold element52, which is formed of resin. The coil 51 is substantially in acylindrical shape and has the outer circumferential periphery and theinner circumferential periphery both being covered with the mold element52. The coil 51 surrounds throughout the outer circumferential peripheryof the pipe 11 in the circumferential direction. The mold element 52 andthe electrical connector 53 are integrally formed from resin. The coil51 is connected with a terminal 55 of the electrical connector 53 via awiring member 54.

The coil 51 has the outer circumferential periphery and the tip end bothprovided with a housing 13. The housing 13 includes a housing bottomportion 131 and a housing outer end 132. The housing bottom portion 131is located around the outer circumferential periphery of the pipe 11 ofthe with-cover pipe member 10. The housing outer end 132 is raised inthe axial direction from the outer end of the housing bottom portion131. The housing 13 is formed from a magnetic material such aselectromagnetic stainless steel. The cover 12 of the with-cover pipemember 10 is provided at the side of the rear end of the coil 51. Thecover 12 surrounds the rear end of the coil 51 and is abutted to thehousing bottom portion 131 in the axial direction. The coil 51, which iscovered with the mold element 52, is surrounded by the pipe 11 of thewith-cover pipe member 10, the cover 12, the housing bottom portion 131of the housing 13, and the housing outer end 132. That is, the coil 51is substantially surrounded by the with-cover pipe member 10 and the twocomponents of the housing 13.

The pipe 11 of the with-cover pipe member 10 has a tip-end-side portion,which accommodates a needle 40. The tip-end-side portion of the pipe 11has a fitting portion 113, which is dented in the radial direction andconfigured to be fitted with a sealing member (not shown), which issubstantially in a ring shape. The sealing member is configured to sealbetween the injector 1 and the engine head when the injector 1 ismounted to the engine head. The pipe 11 of the with-cover pipe member 10has a rear-side portion at the rear side of the fitting portion 113, andthe rear-side portion has the thickness t1. The cover 12 has thethickness t2. The thicknesses t1, t2 satisfy t1≦t2. In the presentembodiment, the thickness t1 satisfies t1=1 mm, and the cover thicknesst2 satisfies t2=1.5 mm.

The pipe 11 of the with-cover pipe member 10 has a tip end 111, whichaccommodates a valve body 31. The valve body 31 is substantially in acylindrical shape, for example, and fixed to the tip end 111 of the pipe11 by press-fitting, welding, or the like. The valve body 31 has aninner wall surface, which is substantially in a conical shape andreduces in the inner diameter toward the tip end thereof. The inner wallsurface of the valve body 31 defines a valve seat 32. The nozzle holes34 are provided in the tip end of the valve body 31. The nozzle holes 34communicate the inside of the valve body 31 with the outside of thevalve body 31. The nozzle holes 34 may be a single hole or multiplehoes.

The needle 40 as a valve element and a moving core 23 are accommodatedaround the inner circumferential periphery of the pipe 11 of thewith-cover pipe member 10. The moving core 23 is axially movable aroundthe inner circumferential periphery of the pipe 11. The moving core 23is substantially in a cylindrical shape and formed from a magneticmaterial such as electromagnetic stainless steel. The moving core 23 hasa through hole 231, which extends substantially in the axial direction.The through hole 231 is configured to therethrough communicate fuel soas to restrict the moving core 23 from sticking an inner connector 21when the moving core 23 is attracted to the inner connector 21. In thepresent structure, the needle 40 can be smoothly manipulated to open andclose the nozzle holes.

The needle 40 is located around the inner circumferential periphery ofthe pipe 11 and substantially coaxial with the valve body 31. The needle40 has a tip end defining a seal portion 42. The seal portion 42 isconfigured to be seated to the valve seat 32 of the valve body 31. Theneedle 40 is substantially in a cylindrical shape and has an innercircumferential periphery defining a needle fuel passage 44. Fuel flowsfrom the needle fuel passage 44 inside the needle 40 into a pipe fuelpassage 14 outside the needle 40 through a fuel hole 45. The needle 40has a rear end, which is fixed to the moving core 23. In the presentstructure, the moving core 23 and the needle 40 are integrally movableback and forth in the axial direction. The moving core 23 and the needle40 may be separate components.

The pipe 11 of the with-cover pipe member 10 has a rear end 112 providedwith a connector member 20. The connector member 20 includes the innerconnector 21 and an outer connector 22. The inner connector 21 islocated around the inner circumferential periphery of the pipe 11. Theouter connector 22 is configured to lead fuel into the pipe 11 from theoutside of the outer connector 22. In the present embodiment, the innerconnector 21 and the outer connector 22 are integrally formed to be theconnector member 20 as the one component (single component). Theconnector member 20 is partially inserted in the axial direction aroundthe inner circumferential periphery of the pipe 11 of the with-coverpipe member 10 and connected with the pipe 11. The connector member 20is substantially in a cylindrical shape and formed from a magneticmaterial such as electromagnetic stainless steel.

An adjusting pipe 25 is press-fitted into the inner circumferentialperiphery of the inner connector 21. The outer connector 22 has a rearend defining a fuel inlet 29. The fuel inlet 29 is supplied with fuel bya fuel pump (not shown) from a fuel tank. Fuel is supplied to the fuelinlet 29, and the fuel flows into a connector fuel passage 24, which isdefined by the inner circumferential periphery of the outer connector21, after passing through a filter member 28. The filter member 28 isprovided inside the outer connector 21. The filter member 28 removesforeign matter contained in the fuel.

The needle 40 has a rear end, which is in contact with a first spring 26as a biasing member. The first spring 26 has one end, which is incontact with the rear end of the needle 40. The first spring 26 has theother end, which is in contact with the adjusting pipe 25. The movingcore 23 has a tip end, which is in contact with a second spring 27 as abiasing member. Each of the biasing members is not limited to the springand may be a blade spring, a gas damper, a liquid damper, or the like.

As described above, the adjusting pipe 25 is press-fitted to the innercircumferential periphery of the inner connector 21. The load exertedfrom the first spring 26 is controlled by adjusting the press-fittedmargin of the adjusting pipe 25. The first spring 26 is extendable inthe axial direction. In the present structure, the moving core 23 andthe needle 40 are integrally biased from the first spring 26 such thatthe seal portion 42 is seated to the valve seat 32. Simultaneously, themoving core 23 is biased from the second spring 27 such that the rearend of the moving core 23 makes contact with a contact surface 401 ofthe needle 40.

Next, an operation of the injector 1 is described.

Referring to FIG. 1, when the coil 51 is de-energized, the innerconnector 21 of the connector member 20 and the moving core 23 do notcause magnetic attraction force therebetween. In the present condition,the moving core 23 is biased by the first spring 26 and moved away fromthe inner connector 21. Consequently, when the coil 51 is de-energized,the seal portion 42 of the needle 40, which is integrated with themoving core 23, is seated to the valve seat 32 to be in a closed state.Therefore, fuel is not injected from the nozzle holes 34.

When the coil 51 is energized, the coil 51 generates a magnetic field tocause magnetic flux through a magnetic circuit defined in the housing13, the pipe 11, the moving core 23, the inner connector 21, and thecover 12. Thus, the inner connector 21 and the moving core 23, which areapart from each other, generate magnetic attraction force therebetween.When the magnetic attraction force, which is generated between the innerconnector 21 and the moving core 23, becomes greater than the biasingforce of the first spring 26, the moving core 23 and the needle 40integrally move toward the inner connector 21. Consequently, the sealportion 42 of the needle 40 is lifted from the valve seat 32 to be in anopened state.

Fuel flows into the fuel inlet 29 and passes through the filter member28, the connector fuel passage 24 inside the outer connector 22, thepassage inside the adjusting pipe 25 and the inner connector 21, and theneedle fuel passage 44 inside the needle 40. The fuel flows into thepipe fuel passage 14 outside the needle 40 through the fuel hole 45. Thefuel flowing into the pipe fuel passage 14 passes through the gapbetween the valve body 31 and the needle 40, which is lifted from thevalve seat 32, and the fuel is injected from the nozzle holes 34.

When the coil 51 is de-energized, the magnetic attraction force betweenthe inner connector 21 and the moving core 23 disappears. In the presentoperation, the moving core 23 and the needle 40 integrally move to theopposite side of the inner connector 21 by being exerted with thebiasing force of the first spring 26. Consequently, the seal portion 42of the needle 40 is again seated to the valve seat 32 to be in theclosed state. Thus, fuel injection from the nozzle holes 34 isterminated.

Next, a manufacturing process of the injector 1 is described.

First, the valve body 31 is attached to the tip end 111 of the pipe 11of the with-cover pipe member 10. Afterwards, the moving core 23 and theneedle 40 are accommodated inside the pipe 11. The moving core 23 isintegrated with the needle 40 by, for example, press-fitting or weldingin advance.

Subsequently, the coil assembly 50, which includes the coil 51, the moldelement 52, the electrical connector 53, is attached to the outercircumferential periphery of the pipe 11 of the with-cover pipe member10. At this time, the coil 51 is located such that the rear end side ofthe coil 51, which is embedded in the mold element 52, is covered thecover 12 of the with-cover pipe member 10. And subsequently, the housing13 is attached to the with-cover pipe member 10. As illustrated in FIG.1, the cover 12 is abutted to the housing bottom portion 131 in theaxial direction. At this time, the housing 13 is attached such that theouter circumferential periphery and the tip end of the coil 51 arerespectively covered with the housing outer end 132 and the housingbottom portion 131.

And subsequently, the connector member 20 is press-fitted into the innercircumferential periphery of the with-cover pipe member 10 from the rearend of the with-cover pipe member 10. The first spring 26 is insertedinto the cavity defined by the inner circumferential periphery of theinner connector 21 of the connector member 20, and subsequently theadjusting pipe 25 is press-fitted to the inner circumferential peripheryof the inner connector 21. Furthermore, the filter member 28 is attachedto the inside of the outer connector 22 of the connector member 20.Thus, the manufacturing of the injector 1 is completed.

Next, an operation effect of the injector (fuel injection valve) 1according to the present embodiment is described. In the injector 1according to the present embodiment, the pipe 11 and the cover 12 areintegrally formed to be the one component (single component) as thewith-cover pipe member 10. In addition, the inner connector 21 and theouter connector 22 are integrally formed to be the one component (singlecomponent) as the connector member 20. Therefore, in the presentstructure, the number of components of the injector can be reduced,compared with the conventional structures in which the pipe 11 and cover12 are separately formed to be multiple components, and/or the innerconnector 21 and the outer connector 22 are separately formed to bemultiple components. Thus, the structure of the injector 1 can besimplified, and therefore productivity and quality of the injector 1 canbe enhanced.

More specifically, a manufacturing process such as aligning of onecomponent relative to another component in the axial direction andfixing of one component to another component by welding or the like canbe reduced by the reduction of the number of components. Therefore, manpower for manufacturing the injector can be reduced, so thatproductivity of the injector can be enhanced. As a whole, a jointportion of components can be reduced. Thus, strength of the injector 1can be enhanced, compared with the conventional structure, and thereforereliability of the injector 1 can be further enhanced.

Further, it is obvious from FIG. 1 (present embodiment) and FIG. 3(prior art), the components are not simply integrally formed to the onecomponents in the present embodiment. In the present embodiment, theconventional pipe 911 is once divided, and the tip-end-side portion ofthe pipe 911 and the cover 912 are integrated into the one component asthe with-cover pipe member 10. In addition, the rear-side portion of thepipe 911, the inner connector 921, and the outer connector 922 areintegrated into the one component as the connector member 20. Thus, thestructure of the injector is totally changed so as to reduce the numberof the components. Therefore, manufacture of each component isfacilitated. Furthermore, in the present structure, the connector member20 is inserted in the axial direction into the inner circumferentialperiphery of the with-cover pipe member 10 and fixed to the with-coverpipe member 10. Therefore, assembling work of the injector is alsofacilitated. Thus, productivity and quality of the injector 1 can beenhanced.

Furthermore, according to the present embodiment, the pipe 11 and thecover 12 are integrally formed to be the one component as the with-coverpipe member 10. In addition, the coil 51 is surrounded by the twocomponents including the with-cover pipe member 10 and the housing 13.Thus, the structure of the injector 1 can be simplified, and thereforeproductivity of the injector 1 can be enhanced. Further, the with-coverpipe member 10 can be coaxially aligned relative to the housing 13 bysimply adjusting the position of the housing 13 in the axial directionrelative to the outer circumferential periphery of the pipe 11 of thewith-cover pipe member 10. That is, the position of the outermostperipheral surface of the housing 13 in the axial direction can beeasily adjusted in accordance with the alignment between the twocomponents including the with-cover pipe member 10 and the housing 13.Therefore, dimensional control at the time of mounting the injector 1 tothe engine or the like can be facilitated, and thereby mountability ofthe injector 1 can be enhanced. Further, in the present structure,accuracy of the location of the injector 1 when mounted to the enginecan be enhanced, and hence product quality such as the fuel injectionangle of the injector 1 can be enhanced.

As described above, according to the present embodiment, productivityand quality of the injector (fuel injection valve) can be enhanced witha simple structure.

Second Embodiment

In the present embodiment, estimation results of static attraction forceof the injector (fuel injection valve) are described. Here, a magneticcircuit model of the injector having the same structure as that in thefirst embodiment is defined. Further, values of static attraction forcehaving different thicknesses t2 (FIG. 1) of the with-cover pipe memberare obtained by conducting a simulation using the magnetic circuitmodel. In the simulation, magnetomotive force is set at 500 AT (500 A)and 1800 AT (1800 A).

Referring to FIG. 1, the static attraction force is equivalent tomagnetic attraction force generated between the inner connector 21 andthe moving core 23 when magnetic flux passes through the magneticcircuit including the housing 131 the pipe 11, the moving core 23, theinner connector 21, the and cover 12 in response to energization of thecoil 51.

FIG. 2 depicts the result of the simulation. FIG. 2 depicts arelationship between the cover thickness t2 (mm) and the staticattraction force (N). It is obvious from FIG. 2, in the case where themagnetomotive force is 500 AT, and the cover thickness t2 is greater orequal to 1.5 mm, stable static attraction force of about 75N can beobtained. Further, in the case where the magnetomotive force is 1800 AT,and the cover thickness t2 is greater or equal to 1.5 mm, stable staticattraction force of about 115N can be obtained. Therefore, the coverthickness t2 is preferably greater or equal to 1.5 mm.

In the above embodiments, the with-cover pipe member 10 may be formed bypress-forming or forging. In the above embodiments, the cover 12 extendsin the radial direction from the outer circumferential periphery of thepipe 11. The cover 12 extends in the circumferential direction aroundthe outer circumferential periphery of the pipe 11. The cover 12 may besubstantially in a collar shape.

It should be appreciated that while the processes of the embodiments ofthe present invention have been described herein as including a specificsequence of steps, further alternative embodiments including variousother sequences of these steps and/or additional steps not disclosedherein are intended to be within the steps of the present invention.

The above structures of the embodiments can be combined as appropriate.Various modifications and alternations may be diversely made to theabove embodiments without departing from the spirit of the presentinvention.

1. A fuel injection valve comprising: a pipe being substantially in acylindrical shape; a coil located radially outside of the pipe andconfigured to generate a magnetic field when being energized; an innerconnector located radially inside of the pipe; a moving core locatedradially inside of the pipe and opposed to the inner connector, themoving core configured to be attracted to the inner connector bymagnetic attraction force generated between the moving core and theinner connector; a valve element movable together with the moving corein an axial direction and configured to open and close a nozzle hole forinjecting fuel; a housing surrounding both an outer circumferentialperiphery of the coil and one axial end of the coil, which is at one endside in the axial direction; a cover surrounding an other axial end ofthe coil, which is at an other end side in the axial direction; an outerconnector configured to lead fuel from an outside of the pipe into thepipe; and a mold element, wherein the pipe and the cover are integrallyformed and one single component as a with-cover pipe member, the innerconnector and the outer connector are integrally formed and an othersingle component as a connector member, the connector member ispartially inserted in the axial direction radially inside the pipe ofthe with-cover pipe member and connected with the pipe, each of thewith-cover pipe member, the connector member, the moving core, and thehousing is formed of a magnetic material, the cover and the housingaccommodate the coil via the mold element, and the cover is abutted to abottom portion of the housing in the axial direction.
 2. The fuelinjection valve according to claim 1, wherein the with-cover pipe memberis formed by press-forming or forging.
 3. The fuel injection valveaccording to claim 1, wherein the pipe of the with-cover pipe member hasa valve-accommodating portion, which accommodates the valve member, thevalve-accommodating portion has a fitting portion, which is dented in aradial direction and configured to be fitted with an annular sealingmember, the pipe has a rear-side portion at a rear side of the fittingportion, the rear-side portion has a thickness t1, the cover has athickness t2, and the thicknesses t1, t2 satisfy t1≦t2.
 4. The fuelinjection valve according to claim 3, wherein the thickness t2 of thecover of the with-cover pipe member is greater than or equal to 1.5 mm.5. The fuel injection valve according to claim 3, wherein the thicknesst1 of the pipe of the with-cover pipe member is greater than or equal to1 mm.
 6. The fuel injection valve according to claim 1, wherein thehousing, the with-cover pipe member, the moving core, the connectormember, and the with-cover pipe member define a magnetic circuit, andthe magnetic circuit therethrough flowing magnetic flux, and the movingcore and the inner connector therebetween generate the magneticattraction force, in response to energization of the coil and generationof the magnetic field.
 7. The fuel injection valve according to claim 1,wherein the cover extends in a radial direction from an outercircumferential periphery of the pipe, the cover extends in acircumferential direction around the outer circumferential periphery ofthe pipe, and the cover is substantially in a collar shape.
 8. The fuelinjection valve according to claim 1, wherein the bottom portion of thehousing in the axial direction is radially protruded inward to define atapered surface, and a portion of the cover is tapered and fitted to thebottom portion of the housing in the axial direction.
 9. The fuelinjection valve according to claim 8, wherein the mold element is formedof resin.
 10. The fuel injection valve according to claim 9, furthercomprising: an electrical connector having a terminal connected with thecoil via a wiring member, wherein the mold element and the electricalconnector are integrally formed from resin.
 11. The fuel injection valveaccording to claim 10, wherein the coil is substantially in acylindrical shape and has an outer circumferential periphery and aninner circumferential periphery both being covered with the moldelement.
 12. The fuel injection valve according to claim 11, wherein thecoil surrounds throughout the outer circumferential periphery of thepipe in the circumferential direction.